Label sheet assembly with improved printer feeding

ABSTRACT

A label sheet assembly and method is disclosed for improving the process of feeding label sheets through a printer. The label sheet assembly may include a facestock layer and a liner sheet. The facestock layer may include an adhesive layer along at least a portion of a first side and include a label surface along at least a portion of the second side opposite the adhesive layer. The facestock layer may include at least one cut line that defines at least one label within the facestock layer while the remaining portions of the facestock layer may be a matrix portion. The matrix portion may include at least one discontinuous cut line spaced from the cut line that defines at least one label wherein the discontinuous cut line may create a zone of decreased bending stiffness along the label sheet assembly.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Utility application Ser. No.15/331,988, titled “LABEL SHEET ASSEMBLY WITH IMPROVED PRINTER FEEDING”,filed on Oct. 24, 2016 which claims priority to U.S. Provisional PatentApplication No. 62/381,714, titled “LABEL SHEET ASSEMBLY WITH IMPROVEDPRINTER FEEDING,” filed Aug. 31, 2016, attorney docket number38208-01654 and to U.S. Provisional Patent Application No. 62/245,369,titled “LABEL SHEET ASSEMBLY WITH IMPROVED PRINTER FEEDING,” filed Oct.23, 2015, attorney docket number 38208-01590, each are herebyincorporated by reference in its entirety.

FIELD OF INVENTION

The present disclosure generally relates to a method and assembly of asheet of labels that is configured to be processed through a printer toprint indicia thereon. More particularly, the disclosure relates to alabel sheet assembly that is configured to be processed through theprinter in an efficient manner.

BACKGROUND

Labels and label sheets are well known and various types have beenproposed to meet the requirements of a wide variety of labelapplications. For example, labels are extensively used in retailbusinesses for communicating product information to customers. Labelsgenerally include a facestock layer with an adhesive side and an exposedside. The exposed side includes a surface for receiving label indiciathereon and is opposite from the adhesive side. A liner sheet isoperably attached to the adhesive side and is configured to allow a userto peel the label portion of the facestock from the liner sheet to beplaced on a substrate. A plurality of cut lines may separate thefacestock layer into a plurality of labels in various arrangements.

Many label sheets are configured to be feed through a printer to printink on the surface of the labels. For example, U.S. Pat. No. 7,709,071to Wong et al. discloses a particular type of label sheet assembly thatis configured to be fed through a printer and also allows a user toeasily remove labels by hand. This patent is incorporated by referencein its entirety. These label sheet assemblies allow a user broaddiscretion as to the orientation of the label and the indicia to beprinted thereon. However, problems arise when a user processes labelsheets through a printer, such as an inkjet printer, desktop printer, orlaser printer. Many printers are configured to receive a label sheet orother sheet and process it through at least one, but usually more thanone, rotary mechanisms during the printing process. These processes maycause portions of the label sheet assembly to become creased,manipulated or otherwise disengaged. This may cause ink to shift orlabels to be moved relative the remaining facestock layer or linersheet. Labels risk damage and indicia may not be accurately printedalong the labels.

Therefore, there is a need for a label sheet assembly having a facestockand liner material that can be configured to reduce inconsistentprocessing through a printer. There is also a need for an improvedmethod of feeding a label sheet through a printer to accurately applyink or indicia thereon without unduly manipulating the orientation ofthe labels or label sheet assembly.

SUMMARY

A label sheet assembly is provided as shown and described herein. Thelabel sheet assembly may include a facestock layer having at least onecut line that defines at least one label and a matrix portion whereinthe facestock layer is configured to receive indicia thereon. Anadhesive layer and a liner sheet layer. A plurality of discontinuous cutlines may be positioned along the matrix portion wherein thediscontinuous cut lines may create a zone of decreased bending stiffnessalong the label sheet assembly. The matrix portion may extend from theat least one label to an edge of the label sheet assembly. The matrixportion may include at least one discontinuous cut line spaced from thecut line that defines at least one label. The facestock layer may be alabel and may include at least one weakened separation line that dividesthe sheet assembly into multiple sections. The facestock layer mayinclude a plurality of edges and the plurality of discontinuous cutlines may be generally parallel relative to each other and have agenerally diagonal orientation relative to the plurality of edges alonga feed direction of the sheet assembly. The label sheet assembly mayinclude a header and an opposite footer wherein the plurality ofdiscontinuous cut lines may be provided along the header or footer ofthe label sheet assembly.

In one embodiment, provided is a label sheet assembly that may include afacestock layer having at least one cut line that defines at least onelabel and a matrix portion. The facestock layer may be configured toreceive indicia thereon. The facestock layer may include a first edgeand an opposite second edge along with a third edge and an oppositefourth edge such that the edges may intersect to form a generallyrectangular sheet assembly wherein the first and second edges define afeed direction such that the label sheet assembly may be configured tobe fed into a conventional printer from the first edge or the secondedge. The label sheet assembly may include a liner sheet layer attachedto the facestock layer with an adhesive layer between the liner sheetlayer and the facestock layer. A plurality of discontinuous cut linesmay be positioned along the matrix portion to create a zone of decreasedbending stiffness along the label sheet assembly. The plurality ofdiscontinuous cut lines may extend between the at least one label andthe first, second, third, and fourth edges. The plurality ofdiscontinuous cut lines may be generally straight cut lines and includea generally diagonal orientation relative to the first, second, third,and fourth edges. The plurality of discontinuous cut lines may be spacedfrom the at least one cut line that defines the label and the first,second, third, and fourth edges. The plurality of discontinuous cutlines may be generally parallel relative to each other and have agenerally diagonal orientation relative to the first and second edgesalong the feed direction of the sheet assembly.

The label sheet assembly may include a first group of the plurality ofdiscontinuous cut lines oriented in a first generally diagonalorientation and a second group of the plurality of discontinuous cutlines oriented in a second generally diagonal orientation wherein thefirst group have an opposite diagonal orientation from the second group.The first group of discontinuous cut lines may extend between the thirdedge and a center axis of the sheet assembly and the second group ofdiscontinuous cut lines may extend between the fourth edge and thecenter axis of the sheet assembly. The first group and second group ofdiscontinuous cut lines may form an apex along the center axis of thesheet adjacent at least one of the first and second edges. The labelsheet may include a first separation line that extends from the firstedge to the second edge and the label sheet may include a secondseparation line that extends from the third edge to the fourth edge. Inone embodiment, the label sheet assembly may include quadrants havingdiscontinuous cut lines arranged within the matrix portions of thefacestock wherein each quadrant includes discontinuous cut linesarranged in a first group oriented in a first generally diagonalorientation or a second group oriented in a second generally diagonalorientation wherein the first group of discontinuous cut lines has anopposite diagonal orientation from the second group.

In another embodiment, provided is a method of feeding a label sheetassembly through a printer. The method may include providing a sheetassembly having a facestock layer, an adhesive layer, and a liner sheet.A cut line may be cut into the facestock layer to define at least onelabel and a matrix portion. At least one discontinuous cut line may bealigned along the matrix portion. At least one discontinuous cut linemay be cut along the matrix portion that is spaced from the cut linethat defines at least one label wherein the discontinuous cut linescreate a zone of decreased bending stiffness along the matrix portion ofthe label sheet assembly. The label sheet assembly may be fed into aprinter to print indicia thereon. In one embodiment, a first group of aplurality of discontinuous cut lines that are oriented in a firstgenerally diagonal orientation may be aligned along the matrix portionand a second group of the plurality of discontinuous cut lines that areoriented in a second generally diagonal orientation may be aligned alongthe matrix portion wherein the first group have an opposite diagonalorientation from the second group. Additionally, the first group and thesecond group of discontinuous cut lines may be aligned to form an apexalong a center axis of the sheet assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Operation of the disclosure may be better understood by reference to thefollowing detailed description taken in connection with the followingillustrations, wherein:

FIG. 1A is a cross sectional view of an embodiment of a label sheetassembly of the present disclosure;

FIG. 1B is a plan view of an embodiment of a label sheet assembly of thepresent disclosure with a plurality of discontinuous cut lines;

FIG. 2 is a plan view of an embodiment of the label sheet assembly witha plurality of separation lines and discontinuous cut lines;

FIG. 3 is a plan view of an embodiment of the label sheet assembly inaccordance with one aspect of the present disclosure;

FIG. 4 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIGS. 5A-5F are plan views of various steps of an embodiment of a methodfor creating the label sheet assembly in accordance with the presentdisclosure;

FIG. 6 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 7 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 8 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 9 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 10 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 11 is a plan view of an embodiment of the label sheet assemblies inaccordance with embodiments of the present disclosure;

FIG. 12 is an illustration of various sheet assemblies after having beenprocessed through a laser printer in accordance with the presentdisclosure;

FIG. 13 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 14 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 15 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 16 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 17 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 18 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure;

FIG. 19 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure; and

FIG. 20 is a plan view of an embodiment of the label sheet assembly inaccordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the presentdisclosure, examples of which are illustrated in the accompanyingdrawings. It is to be understood that other embodiments may be utilizedand structural and functional changes may be made without departing fromthe respective scope of the disclosure. Moreover, features of thevarious embodiments may be combined or altered without departing fromthe scope of the disclosure. As such, the following description ispresented by way of illustration only and should not limit in any waythe various alternatives and modifications that may be made to theillustrated embodiments and still be within the spirit and scope of thedisclosure.

A label sheet assembly 10 is disclosed and may be of any appropriateconfiguration and is not limited to that shown and described herein. Itshould similarly be understood that the sheet assembly 10 may be adaptedto any appropriate size, including, without limitation, 8.5 inches by 11inches, A4 size, legal size or any other size. The sheet assembly 10 maybe made of any appropriate materials and colors or indicia and thisdisclosure is not limited in this regard.

FIG. 1A is a cross sectional side view of the sheet assembly 10 that mayinclude a facestock layer 20 which may be coated with a pressuresensitive adhesive layer 30. Sheet assembly 10 may also include a linersheet 40 attached to the adhesive layer 30. The liner sheet 40 mayinclude a release coating for supporting the adhesive layer 30. Theliner sheet 40 may be made of any appropriate material, including,without limitation a calendared paper or polymer film. The facestocklayer 20 may be of any appropriate material, including withoutlimitation a paper, plastic or polymer material such as a polyestermaterial or other transparent, translucent or semi-translucent material.The facestock layer 20 may also be a laminate or a label or combinationof both. The facestock layer may have a top surface 22 that isconfigured to receive indicia thereon.

As illustrated by FIG. 1B, the top surface 22 of facestock layer 20 ofthe sheet assembly 10 is shown in plan view. The sheet assembly 10 mayinclude at least one cut line 50 that may extend through the facestocklayer 20 to separate that sheet assembly into at least one label 60 anda matrix portion 70. In this embodiment, the facestock layer 20 includessix (6) labels 60 having a generally rectangular shape with roundedcorners. However, this application is not limited as to theconfiguration, amount, or size of the labels 60. Various embodiments ofthese particular sizes are illustrated by FIGS. 2-4 and 6-10 of whichthis application is not merely limited to these configurations. Thelabel sheet assembly 10 may include a first edge 12 and opposite secondedge 14 along with a third edge 16 and opposite fourth edge 18. Theseedges 12, 14, 16, 18 may intersect to form a generally rectangular sheetassembly wherein the label sheet assembly 10 may be configured to be fedinto a conventional printer from any edge.

In the embodiment of FIG. 1B, the label sheet assembly 10 may include aplurality of discontinuous cut lines 80 positioned along the matrixportion 70. The discontinuous cut lines 80 may extend between the labels60 and the first, second, third, and fourth edges 12, 14, 16, 18 asillustrated. The plurality of discontinuous cut lines 80 may begenerally straight cut lines and may have a generally diagonalorientation relative to the edges and may be spaced from the cut lines50 and the edges 12, 14, 16, 18. The plurality of discontinuous cutlines 80 may be generally parallel relative to each other and have agenerally diagonal orientation relative to the first and second edges12, 14 or otherwise along the feed direction of the sheet assembly 10.Further, there may be a first group 82 of discontinuous cut lines 80that are oriented in a first generally diagonal orientation and a secondgroup 84 of discontinuous cut lines that are oriented in a secondgenerally diagonal orientation. The first group 82 may have an oppositediagonal orientation from the second group 84. The first group 82 ofdiscontinuous cut lines 80 may extend between the third edge 16 to acenter axis 90 of the sheet 10 along the first and second edges 12, 14.The second group 84 of discontinuous cut lines 80 may extend between thefourth edge 18 to the center axis 80 of the sheet 10 along the first andsecond edges 12, 14. The first group and second group 82, 84 may form anapex 92 along the center axis of the sheet 10 adjacent the first andsecond edges 12, 14.

As such, known facestock and liner layers may have experienceddifficulty being fed through printers due to the level of rigidity ofthe sheet assembly. The discontinuous cut lines 80 are added to improvethe way in which label sheet assemblies 10 are fed through printers toreceive indicia on the labels. The discontinuous cut lines 80 may reducelifting, shifting, or bending of the matrix portion 70 relative to theliner layer 40 and the labels 60 while undergoing stresses caused byprocessing the label sheet assembly 10 though the printer. Thediscontinuous cut lines 80 may have various orientations that reducebending stiffness of the assembly without creating a sharp bend in thesheet after being processed through a printer. The discontinuous cutlines 80 may extend through the facestock layer 20. Alternatively, thediscontinuous cut lines may extend through the facestock layer 20 andthe liner layer 40. These cuts 80 may be kiss cut to maintain sheetintegrity.

The discontinuous cut lines 80 may be placed along the sheet to create aweakened region that helps to allow the sheet to fold along this region.These cut lines 80 may be strategically placed relative to a grouping oflabels 60 in alignment along the top or bottom thereof. Additionally,the design discontinuous cut lines 80 may be centered along a header 120or footer 130 of the label sheet assembly 10. The weakened region couldbe a perforation or it could be a region with less material, or lowercaliper, which makes the region a preferred area to fold. Additionally,the discontinuous cut lines 80 may reduce stiffness of the header 120 orfooter 130 regions of the label sheet assembly by breaking fiberformation along the first and second edges 12, 14. The discontinuous cutlines 80 may reduce the bending resistance of the leading edges 12 andtrailing edges 14 of the label sheet assembly 10 and may be formed suchthat they have minimal impact on the smoothness of the liner sheet 40 tominimize likelihood of adjacent sheets to nest or stick together.Otherwise, sheet nesting of adjacent sheets may result in the error ofmore than one sheet being fed into a printer at once.

FIG. 2 illustrates a sheet assembly 10 having a plurality of die cutlines 50 that define a plurality of labels 60. In this embodiment, aplurality of weakened separation lines 100 may extend from the firstedge 12 to the second edge 14. The weakened separation lines 100 may beformed through portions of the facestock layer 20 along the matrixportion 70 and formed through the liner sheet 40. The weakenedseparation lines 100 and label sheet assembly 10 may be configured asdescribed by commonly owned U.S. Pat. No. 7,709,071, which isincorporated herein by reference. In the embodiment of FIG. 2, the labelsheet assembly 10 may include a plurality of discontinuous cut lines 80positioned along the matrix portion 70. The discontinuous cut lines 80may extend between the labels 60 and the first, second, third, andfourth edges 12, 14, 16, 18 as illustrated. The plurality ofdiscontinuous cut lines 80 may each have a common length. The pluralityof discontinuous cut lines 80 may have a generally diagonal orientationrelative to the edges 12, 14, 16, 18 and may be spaced from the cutlines 50 and the edges 12, 14, 16, 18. The plurality of discontinuouscut lines 80 may be generally parallel relative to each other. Further,there may be a first group 82 of discontinuous cut lines 80 that areoriented in a first diagonal orientation and a second group 84 ofdiscontinuous cut lines that are oriented in a second diagonalorientation. The first group 82 may have an opposite diagonalorientation from the second group 84. The first group 82 ofdiscontinuous cut lines 80 may extend between the third edge 16 to acenter axis 90 of the sheet 10 along the first and second edges 12, 14.The second group 84 of discontinuous cut lines 80 may extend between thefourth edge 18 to the center axis 80 of the sheet 10 along the first andsecond edges 12, 14. The first group and second group 82, 84 may form anapex 92 along the center axis of the sheet 10 adjacent the first andsecond edges 12, 14.

FIG. 3 illustrates an embodiment of the sheet assembly 10 having aplurality of die cut lines 50 that define a plurality of labels 60. Inthis embodiment, the labels 60 are defined by cut lines 50 having atleast one curvilinear side 110. In the embodiment of FIG. 3, the labelsheet assembly 10 may include a plurality of discontinuous cut lines 80positioned along the matrix portion 70. The discontinuous cut lines 80may extend between the labels 60 and the first, second, third, andfourth edges 12, 14, 16, 18 as illustrated. The plurality ofdiscontinuous cut lines 80 may each have a common length along thesecond edge 14. Additionally, the plurality of discontinuous cut lines80 may each have different lengths adjacent the first edge 12 such thatthe discontinuous cut lines 80 may extend between the curvilinear side110 of the labels 60 and the first edge 12 of the assembly 10. Theplurality of discontinuous cut lines 80 may have a generally diagonalorientation relative to the edges and may be spaced from the cut lines50 and the edges 12, 14, 16, 18. The plurality of discontinuous cutlines 80 may be generally parallel relative to each other. Further,there may be a first group 82 of discontinuous cut lines 80 that areoriented in a first generally diagonal orientation and a second group 84of discontinuous cut lines that are oriented in a second generallydiagonal orientation. The first group 82 may have an opposite diagonalorientation from the second group 84, but the present teachings are notlimited to this configuration. The first group 82 of discontinuous cutlines 80 may extend between the third edge 16 to the center axis 90 ofthe sheet 10 along the first and second edges 12, 14. The second group84 of discontinuous cut lines 80 may extend between the fourth edge 18to the center axis 80 of the sheet 10 along the first and second edges12, 14. The first group and second group 82, 84 may form an apex 92generally along the center axis of the sheet 10 adjacent the first andsecond edges 12, 14.

FIG. 4 illustrates an embodiment of the sheet assembly 10 having aplurality of die cut lines 50 that define a plurality of labels 60. Inthis embodiment, the labels 60 are defined by cut lines 50 having atleast one curvilinear side 110. In the embodiment of FIG. 4, the labelsheet assembly 10 may include a plurality of discontinuous cut lines 80positioned along the matrix portion 70. The discontinuous cut lines 80may extend between the labels 60 and the first, second, third, andfourth edges 12, 14, 16, 18 as illustrated. The plurality ofdiscontinuous cut lines 80 may each have a common length and bepositioned between the first edge 14 and the curvilinear side 110 of theplurality of labels 60. Additionally, the plurality of discontinuous cutlines 80 may each have common lengths. The discontinuous cut lines 80may have a generally parallel orientation relative to the first edge 12.The plurality of discontinuous cut lines 80 may also have an offsetorientation relative to each other as they extend between the third edge16 and the fourth edge 18

FIGS. 5A-5F illustrate a method of creating the label sheet assembly 10with a plurality of discontinuous cut lines 80. The facestock layer 20may be provided with the adhesive layer 30 along a first side and anindicia substrate 22 along an opposite second side. The liner sheet 40may be attached to the adhesive layer 30 of the facestock layer 40. Asillustrated by FIG. 5A, at least one cut line 50 is cut into thefacestock layer 40 to define at least one label 60 and a matrix portion70 of the facestock layer. FIG. 5A illustrates an example of a knowndesign for a label sheet assembly. FIG. 5B illustrates a referencedesign for a plurality of discontinuous cut lines 80. In one embodiment,the discontinuous cut lines 80 are positioned adjacent a header 120 andfooter 130 portions of the layout. The plurality of discontinuous cutlines 80 may each be generally straight and positioned in a relativelydiagonal orientation relative to the edges along the header and footer.FIG. 5C illustrates the reference design of FIG. 5B positioned over thesheet assembly of FIG. 5A. In this embodiment, various adjustments maybe made to the orientation of the various cut lines and perimeter of thelabel sheet assembly. For example, any perimeter strip cuts may beremoved and weakened separations lines may be extended to the edgesalong the perimeter of the sheet assembly. In FIG. 5D, additional layoutadjustments may be made to align the discontinuous cut lines 80 with theplurality of labels 60. In particular, the labels may be offset orpositioned a dimension such as approximately 0.125″ while the weakenedseparation lines may be offset a different dimension such asapproximately 0.0625″. At least one discontinuous cut line may be cutwithin the matrix portion and may be spaced from the cut line thatdefines at least one label such that the discontinuous cut line maycreate a zone of decreased bending stiffness along the matrix portion ofthe label sheet assembly. The label sheet assembly may be fed into aprinter to print indicia thereon.

In one embodiment, the dimensions of the first and second edges 12, 14may be between approximately 5 inches and 11 inches, or may beapproximately 8.5 inches. The dimension of the third and fourth edges16, 18 may be between approximately 7 inches and 18 inches, or morenarrowly between approximately 11 inches and 14 inches. Alternately, thedimensions of the sheet assembly 10 may include dimensions that compareto standard US paper sizes including letter (8.5×11 in), legal (8.5×14in), junior legal (5×8 in), and ledger/tabloid (11×17 in) sizes orstandard international paper sizes such as A, B, and C paper sizes.

As illustrated by FIGS. 6-10, the label sheet assembly 10 may includevarious configurations having particular dimensions of facestock layers,labels, and matrix portions. The particular arrangement of discontinuouscut lines 80 in relation to the cut lines 50 that define the pluralityof labels 60 and the matrix portion 70 provide a particular improvementover the prior art. In particular, the configuration of discontinuouscut lines 80 as illustrated by the embodiments of FIGS. 6-10 providereduced bending stiffness of the label sheet assembly 10 as it is beingfed through a printer.

The discontinuous cut lines 80 may be spaced from one anotherapproximately 0.5″ along the header and footer of the assembly.Additionally, the diagonal orientation of the discontinuous cut lines 80may be between about 30 degrees to about 60 degrees relative to thefirst edge 12 and more particular may be about 45 degrees from the firstedge 12. As illustrated by FIG. 7, the plurality of discontinuous cutlines 80 may be spaced inwardly from the first edge 12 and the thirdedge 16 about 1.125″ as the plurality of discontinuous cut lines 80 maybe spaced from one another about 0.5″. The labels defined within thefacestock layers may have various sizes and configurations asillustrated by FIGS. 6-10 and this disclosure is not limited as such.The diagonal orientation of the discontinuous cut lines 80 may impartreduction in bending stiffness in the margins of the label sheetassembly 10 without concerns that the weakened matrix area may becometoo flexible and prematurely bend at an infeed area of printers. It maybe likely that discontinuous cut lines positioned generally horizontalrelative to the first and second edges 12, 14 may be subject topremature bending at the infeed areas of printers.

FIG. 11 is a plan view of various embodiments of label sheet assemblies10 in accordance with embodiments of the present disclosure. Here four(4) label sheet assemblies 10 are illustrated, each having labels 60formed in a generally circular shape wherein each label sheet assembly10 includes twenty four (24) labels. However, various label shapes andamounts are contemplated and this disclosure is not limited in thisregard. In these embodiments, each label sheet 10 includes fourquadrants or groups as will be further described relative to FIGS. 14and 16. In each group, the discontinuous cut lines 80 may be oriented ina common diagonal pattern along the matrix portion including along theheader and footer areas as well as between portions of the labels 60.The discontinuous cut lines 80 may be generally parallel to one anotherand include various angles and spacing distances from one another.

In the first and second column of groups of the label assemblies 10 ofFIG. 11, the discontinuous cut lines 80 include an angled orientation ineither a first direction or an opposite second direction relative to theedges of the assembly. Additionally, each of the discontinuous cut lines80 may be spaced from one another by approximately 10 mm (approximately0.4″) as the discontinuous cut lines 80 may be positioned along thematrix portion 70. There may be about sixteen (16) discontinuous cutlines 80 being in general alignment that do not intersect with the cutlines 50 that define the labels 60. However, any number of discontinuouscut lines 80 may be oriented in various arrangements along the matrix70.

In the third and fourth columns of groups of the label assemblies 10 ofFIG. 11, the discontinuous cut lines 80 include an angled orientation ineither a first direction or an opposite second direction. Additionallyeach of the discontinuous cut lines 80 may be spaced from one another byvarious distances including about 10 mm (0.4″), 15 mm (0.6″), 20 mm(0.8″), 25 mm (1.0″), 30 mm (1.2″), and 35 mm (1.4″) wherein each ofthese spacing distances are approximates. These spacing distances may begenerally progressive along the surface of the matrix 70 wherein eachsubsequent discontinuous cut line 80 may be spaced further from the lastbeginning at the corner of the assembly 10. For example, there may be adiscontinuous cut line 80 spaced from the next discontinuous cut lineabout 10 mm at a corner of the assembly 10 wherein the nextdiscontinuous cut line 80 is spaced 15 mm, the next being 20 mm, thenext being 25 mm and so on. There may be about seven (7) discontinuouscut lines arranged along the matrix 70 being in general alignment thatdo not intersect with the cut lines 50 that define the labels 60.However, any number of discontinuous cut lines 80 may be used in variousarrangements along the matrix 70.

The diagonal orientation of the discontinuous cut lines 80 may impartreduction in bending stiffness in the margins of the label sheetassembly 10 without concerns that the weakened matrix area may becometoo flexible and prematurely bend at an infeed area of printers. It maybe likely that discontinuous cut lines 80 may improve printer feeding aswell as improve a curling effect that may occur after a label sheetassembly has been processed through a printer.

FIG. 12 is an illustration of various sheet assemblies after having beenprocessed through a printer device that has been found to cause curlingto label sheets. Sheet assemblies 150, 160, and 170 illustrate variousembodiments of the use of discontinuous cut lines 80 positioned alongthe matrix 70 of various embodiments of sheet assemblies 10. Each sheetassembly 150, 160, 170, has been passed through a printer device andexperiences various degrees of curling due to the printing process. Inthese embodiments, the curling effect is upwards towards the printablesurface portion of the labels 60.

Label sheet assembly 150 includes a plurality of round labels thereonand a plurality of discontinuous cut lines 80. Sheet assembly 150illustrates a substantial degree of curling after having been processedthrough a printer device.

Label sheet assembly 160 includes a plurality of round labels 60 thereonand ten (10) more discontinuous cut lines 80 than label sheet assembly150. Label sheet assembly 160 illustrates a lesser degree of curlingafter having been processed through a printer device than label sheetassembly 150.

Label sheet assembly 170 includes a plurality of round labels 60 thereonand twenty (20) more discontinuous cut lines 80 than label sheetassembly 150. Label sheet assembly 170 illustrates a lesser degree ofcurling after having been processed through a printer device than bothlabel sheet assembly 150 and label sheet assembly 160. The configurationof the plurality of discontinuous cut lines 80 may be arranged toimprove the ability of the label sheet 10 to be processed through aprinter and reduce curling effect. This may allow processed label sheets10 to be stacked against one another without becoming stuck or to reducenesting between stacked label sheets 10. Notably, the embodimentsillustrated by FIGS. 13 through 20 improve on the lay-flat propertiesexperienced by the label sheet assemblies 150, 160, and 170 such thatthey experienced a reduced curling effect after being processed througha printer, such as a laser printer.

FIGS. 13 through 20 illustrate various additional embodiments of thesheet assembly 10 in accordance with the present disclosure. FIG. 13illustrates a sheet assembly 10 having a plurality of die cut lines 50that define a plurality of labels 60 along the facestock 20. The labelsheet assembly 10 may include a plurality of discontinuous cut lines 80positioned along the matrix portion 70. The discontinuous cut lines 80may extend between the labels 60 and the first, second, third, andfourth edges 12, 14, 16, 18 as illustrated. The plurality ofdiscontinuous cut lines 80 may be generally straight cut lines and mayhave a generally diagonal orientation relative to the edges and may bespaced from the cut lines 50 and the edges 12, 14, 16, 18.Alternatively, the plurality of discontinuous cut lines 80 may intersectthe edges 12, 14, 16, 18 or the cut lines 50. The plurality ofdiscontinuous cut lines 80 may be generally parallel relative to eachother and have a generally diagonal orientation relative to the firstand second edges 12, 14 or otherwise along the feed direction of thesheet assembly 10. The label sheet 10 of FIG. 13 includes a firstseparation line 190 that may separate the label sheet 10. The firstseparation line 190 may extend between the first edge 12 and the secondedge 14. A second separation line 194 may also separate the label sheet10. The second separation line 194 may extend between the third edge 16and the fourth edge 18. In one embodiment, as illustrated by FIG. 13,the separation lines 190, 194 are weakened separation lines with aplurality of cuts and ties. These separation lines 190, 194 may separatethrough the label sheet 10 along mid points of the respective edges. Inanother embodiment, as illustrated by FIG. 14, the separation lines 190,194 may be cut lines along the matrix 70 that define the perimeter ofvarious sheets of labels that make up the label sheet 10 and may bedetached from one another to peal or otherwise dispense labels 60 fromthe sheets 10 after having received indicia thereon such as through aprinting operation. These various sheets may have different groups orarrangements of the discontinuous cut lines 80 and labels 60 as will bediscussed below. In yet another embodiment, as illustrated by FIG. 15,the label sheet 10 may not include separation lines 190, 194 but mayinclude various quadrants having discontinuous cut lines 80 as arrangedwithin the matrix 70 portions of the facestock 20. The quadrants may bearranged with discontinuous cut lines 80 as described below. Further,any quantity, shape, and type of separation lines 190, 194 may beutilized along the label sheet 10 and this disclosure is not limited inthis regard.

The label sheet 10 may include a first group 82 of discontinuous cutlines 80 that are oriented in a first generally diagonal orientation anda second group 84 of discontinuous cut lines that are oriented in asecond generally diagonal orientation. The first group 82 ofdiscontinuous cut lines 80 may have an opposite diagonal orientationfrom the second group 84. The first group 82 of discontinuous cut lines80 may extend between the third edge 16, the first edge 12, the firstseparation cut line 190, and the second separation cut line 194. Thesecond group 84 of discontinuous cut lines 80 may extend between thefourth edge 18, the first edge 12, the first separation cut line 190,and the second separation cut line 194. The first group and second group82, 84 may include discontinuous cut lines 80 aligned in a configurationthat forms an apex 92 along the first separation cut line 190 of thesheet 10 adjacent the first edge 12.

Additionally, there may be a third group 86 of discontinuous cut lines80 that are oriented in the second generally diagonal orientation and afourth group 88 of discontinuous cut lines that are oriented in thefirst generally diagonal orientation. The third group 86 may have anopposite diagonal orientation from the fourth group 88. In oneembodiment, the third group 86 may have a similar diagonal orientationas the second group 84 and the fourth group 88 may have a similardiagonal orientation as the first group 82. The third group 82 ofdiscontinuous cut lines 80 may extend between the third edge 16, thesecond edge 14, the first separation cut line 190, and the secondseparation cut line 194. The fourth group 88 of discontinuous cut lines80 may extend between the fourth edge 18, the second edge 14, the firstseparation cut line 190, and the second separation cut line 194.

Further, as illustrated by FIGS. 16, 17, and 18, the label sheet 10 mayinclude discontinuous cut lines 80 arranged in various orientations. Thefacestock 20 may include various quantities of cut lines 50 to definethe labels 60 thereon. As such the various number and size of the labels60 may effect the quantity and arrangement of the discontinuous cutlines 80 positioned along the label sheet 10. FIG. 16 illustrates anembodiment having a greater number of discontinuous cut lines 80 thanthe label sheet 10 illustrated by FIG. 14. Here, the first group 82 andthe third group 86 may include discontinuous cut lines 80 aligned in aconfiguration that forms an apex 92 along the second separation cut line194 of the sheet 10 adjacent the third edge 16. The second group 84 andthe fourth group 88 may include discontinuous cut lines 80 aligned in aconfiguration that forms an apex 92 along the second separation cut line194 of the sheet 10 adjacent the fourth edge 18. As such, the pluralityof spaced discontinuous cut lines 80 of each group may be generallyaligned with each other group relative to the separation lines 190, 194.

FIG. 17 illustrates an embodiment of the label sheet 10 havingdiscontinuous cut lines with generally progressive spacing along thesurface of the matrix 70 wherein each subsequent discontinuous cut line80 may be spaced further from the last. For example, there may be adiscontinuous cut line 80 spaced from the next discontinuous cut lineabout 10 mm at a corner of the assembly 10 wherein the nextdiscontinuous cut line 80 is spaced 15 mm, the next being 20 mm, thenext being 25 mm and so on. There may be about seven (7) discontinuouscut lines arranged along the matrix 70 being in general alignment thatdo not intersect with the cut lines 50 that define the labels 60.However, any number of discontinuous cut lines 80 may be used in variousarrangements along the matrix 70.

FIG. 18 illustrates an embodiment wherein the label sheet 10 includes aplurality of labels 60 without separation lines 190, 194. Here, thelabels 60 may be aligned along a position that generally separates thegroups 82, 84, 86, and 88 and angular configuration of the discontinuouscut lines 80 from each group. The discontinuous cut lines 80 mayintersect the edges or the labels. Also, the discontinuous cut lines mayspaced from the edges and the labels.

As illustrated by FIGS. 19 and 20, the discontinuous cut lines 80 may bearranged in various patterns along the matrix 70 of the label sheet 10.The discontinuous cut lines 80 may be shaped as an intersecting pattern82 such as crosses or as an “x” while aligned along the matrix 70 of thelabel sheet 10. These intersecting patterns 82 may be arranged inaligned rows or in a scattered random orientation. Also, various sizeddiscontinuous cut lines 80 may be used and various number ofintersection patterns 82 are contemplated. The intersecting patterns 82may extend along the entire matrix 70 of the label sheet 10 or only bepositioned along a portion of the label sheet 10 such as along theheader or as along the footer and this disclosure is not limited.

Although the embodiments of the present invention have been illustratedin the accompanying drawings and described in the foregoing detaileddescription, it is to be understood that the present invention is not tobe limited to just the embodiments disclosed, but that the inventiondescribed herein is capable of numerous rearrangements, modificationsand substitutions without departing from the scope of the claimshereafter. The features of each embodiment described and shown hereinmay be combined with the features of the other embodiments describedherein. The claims as follows are intended to include all modificationsand alterations insofar as they come within the scope of the claims orthe equivalent thereof

What is claimed is:
 1. A method of feeding a label sheet assemblythrough a printer device, the method comprising: providing a sheetassembly having a facestock layer, an adhesive layer, and a liner sheet;cutting a cut line into the facestock layer to define at least one labeland a matrix portion; cutting a plurality of discontinuous cut lines inthe facestock layer along the matrix portion wherein the plurality ofdiscontinuous cut lines are spaced from the cut line that defines atleast one label wherein the discontinuous cut lines create a zone ofdecreased bending stiffness along the matrix portion of the label sheetassembly; and feeding the label sheet assembly into a printer device toprint indicia on the at least one label.
 2. The method of claim 1,further comprising the step of aligning a first group of the pluralityof discontinuous cut lines oriented in a first generally diagonalorientation along the matrix portion and aligning a second group of theplurality of discontinuous cut lines oriented in a second generallydiagonal orientation along the matrix portion wherein the first grouphave an opposite diagonal orientation from the second group.
 3. Themethod of claim 2, further comprising aligning the first group and thesecond group of discontinuous cut lines to form an apex along a centeraxis of the sheet assembly.
 4. The method of claim 1, further comprisingthe step of aligning a plurality of discontinuous cut lines that aregenerally straight cut lines along the header or footer of the facestocklayer.
 5. The method of claim 4, further comprising the step of aligninga first group of the plurality of discontinuous cut lines oriented in afirst generally diagonal orientation along the matrix portion andaligning a second group of the plurality of discontinuous cut linesoriented in a second generally diagonal orientation along the matrixportion wherein the first group have an opposite diagonal orientationfrom the second group.
 6. The method of claim 5, further comprisingaligning the first group and the second group of discontinuous cut linesto form an apex along a center axis of the sheet assembly.
 7. The methodof claim 1, wherein said discontinuous cut lines reduce lifting,shifting, or bending of the matrix portion relative to the liner layerwhen the label sheet assembly is processed through a printer device. 8.The method of claim 1, wherein said discontinuous cut lines reduce acurling effect when the label sheet assembly is processed through aprinter device.
 9. The method of claim 1 further comprising providing atleast one weakened separation line along the facestock layer.
 10. Themethod of claim 9 further comprising providing at least one weakenedseparation line along the liner sheet layer.
 11. A method of providing alabel sheet assembly configured to be processed through a printerdevice, the method comprising: providing a sheet assembly having afacestock layer, an adhesive layer, and a liner sheet, the facestocklayer includes a first edge with an opposite second edge, and a thirdedge with an opposite fourth edge such that the edges intersect to forma generally rectangular sheet assembly wherein the first and secondedges define a feed direction such that the label sheet assembly isconfigured to be fed into a printer device from the first edge or thesecond edge, said liner sheet layer is attached to the facestock layerwith said adhesive layer between said liner sheet layer and saidfacestock layer; cutting a cut line into the facestock layer to defineat least one label and a matrix portion; and cutting a plurality ofdiscontinuous cut lines in the facestock layer along the matrix portionwherein the plurality of discontinuous cut lines are spaced from the cutline that defines at least one label, the discontinuous cut lines aregenerally straight cut lines and are configured to create a zone ofdecreased bending stiffness along the matrix portion of the label sheetassembly; and
 12. The method of claim 11 further comprising the step offeeding the label sheet assembly into a printer device to print indiciathereon.
 13. The method of claim 11, wherein the plurality ofdiscontinuous cut lines are positioned adjacent along either the firstedge or the second edge and have a generally diagonal orientationrelative to the first and second edges along the feed direction of thesheet assembly.
 14. The method of claim 12 further comprising cutting afirst group of the plurality of discontinuous cut lines oriented in afirst generally diagonal orientation and a second group of the pluralityof discontinuous cut lines oriented in a second generally diagonalorientation wherein the first group have an opposite diagonalorientation from the second group wherein the first group ofdiscontinuous cut lines extend between the third edge to a center axisof the sheet assembly and the second group of discontinuous cut linesextend between the fourth edge to the center axis of the sheet assembly.15. The method of claim 14, wherein the first group and second group ofdiscontinuous cut lines form an apex along the center axis of the sheetadjacent to at least one of the first and second edges.
 16. The methodof claim 11, wherein said discontinuous cut lines reduce lifting,shifting, or bending of the matrix portion relative to the liner layerwhen the label sheet assembly is processed through a printer device. 17.The method of claim 11, wherein the discontinuous cut lines reduce acurling effect when the label sheet assembly is processed through aprinter device.
 18. The method of claim 11, wherein the discontinuouscut lines extend between the at least one label and the first, second,third, and fourth edges.
 19. The method of claim 11, wherein theplurality of discontinuous cut lines are generally parallel relative toeach other.
 20. The method of claim 11 further comprising providing atleast one weakened separation line that extends from the first edge tothe second edge.